Heat exhanger

ABSTRACT

A heat exchanger is provided through which first and second fluids flow in a heat transfer arrangement. The heat exchanger includes a plurality of laminates. Each laminate includes a plurality of primary heat transfer surfaces disposed to contact the first and second fluids and a plurality of secondary heat transfer surfaces disposed to contact the first and/or second fluid. The respective pluralities of the primary and secondary heat transfer surfaces are configured to form respective pluralities of first and second flow pathways along which the first and second fluids flow, respectively, in the heat transfer arrangement. At least one of the plurality of the primary heat transfer surfaces is corrugated along a length of at least one of the plurality of the first flow pathways.

BACKGROUND OF THE INVENTION

The subject matter disclosed herein relates to a heat exchanger and, more particularly, to a heat exchanger including a plurality of laminates.

To date, heat exchangers for various applications, such as aerospace applications, have traditionally been constructed by either plate/fin technology or tube/shell technology. Both technologies have their advantages and disadvantages. In the latter case, a first fluid is supplied to an interior of a given body, which is formed of thermally conductive materials, and a second fluid is supplied to an exterior of the given body such that heat transfer occurs between the first and second fluids across the thermally conductive materials. In the former case, separating plates formed of thermally conductive materials are provided between the first and second fluids.

BRIEF DESCRIPTION OF THE INVENTION

According to one aspect of the invention, a heat exchanger is provided through which first and second fluids flow in a heat transfer arrangement. The heat exchanger includes a plurality of laminates. Each laminate includes a plurality of primary heat transfer surfaces disposed to contact the first and second fluids and a plurality of secondary heat transfer surfaces disposed to contact the first and/or the second fluid. The respective pluralities of the primary and secondary heat transfer surfaces are configured to form respective pluralities of first and second flow pathways along which the first and second fluids flow, respectively, in the heat transfer arrangement. At least one of the plurality of the primary heat transfer surfaces is corrugated along a length of at least one of the plurality of the first flow pathways.

According to another aspect of the invention, a heat exchanger is provided through which first and second fluids flow in a heat transfer arrangement. The heat exchanger includes a plurality of laminates. Each laminate includes a plurality of primary heat transfer surfaces disposed to contact the first and second fluids and a plurality of secondary heat transfer surfaces disposed to contact the first and/or the second fluid. The respective pluralities of the primary and secondary heat transfer surfaces are configured to form respective pluralities of first and second flow pathways along which the first and second fluids flow, respectively, in the heat transfer arrangement. Each of the plurality of the primary heat transfer surfaces are corrugated along respective lengths of each of the plurality of the first flow pathways.

According to yet another aspect of the invention, a heat exchanger is provided and includes a plurality of laminates coupled together to form a heat exchanger body through which first and second fluids flow in transverse directions, each one of the plurality of the laminates including segments of a plurality of primary heat transfer surfaces disposed to contact the first and second fluids and segments of a plurality of secondary heat transfer surfaces disposed to contact the first and/or the second fluid. The segments of the respective pluralities of the primary and secondary heat transfer surfaces are configured to form respective pluralities of first and second flow pathways along which the first and second fluids flow, respectively, in a heat transfer arrangement, and at least one of the plurality of the primary heat transfer surfaces is corrugated along a length of at least one of the plurality of the first flow pathways

These and other advantages and features will become more apparent from the following description taken in conjunction with the drawings.

BRIEF DESCRIPTION OF THE DRAWING

The subject matter, which is regarded as the invention, is particularly pointed out and distinctly claimed in the claims at the conclusion of the specification. The foregoing and other features, and advantages of the invention are apparent from the following detailed description taken in conjunction with the accompanying drawings in which:

FIG. 1 is a perspective view of a heat exchanger according to one embodiment;

FIG. 2 is an enlarged side view of the heat exchanger of FIG. 1;

FIG. 3 is an enlarged perspective view of the heat exchanger of FIG. 1 showing the laminates thereof; and

FIG. 4 is an enlarged side view of an alternative embodiment of a heat exchanger.

The detailed description explains embodiments of the invention, together with advantages and features, by way of example with reference to the drawings.

DETAILED DESCRIPTION OF THE INVENTION

In accordance with aspects of the invention, laminated technology and emerging additive technologies, such as Direct Metal Laser Sintering (DMLS), enable changes to conventional heat exchanger design. In particular, shaped separating plates can be created leading to increased primary surface area and improved thermal performance.

With reference to FIGS. 1-3, a heat exchanger 10 is illustrated. The heat exchanger 10 includes a plurality of laminates 11 that are each coupled together along a first (width) dimension D1 to form a heat exchanger body 20 through which first and second airflows or fluids (hereinafter referred to as “fluids”) F1 and F2, such as a first flow and a second flow, flow in directions defined along a second (length) dimension D2 and the first dimension D1, respectively. The first and second dimensions D1 and D2 as well as a third (height) dimension D3 are each oriented transversely to one another. Although the first fluid F1 and the second fluid F2 are described herein as fluids, they are not necessarily limited to that case and may include airflows and/or any type of fluids, such as oil, water, refrigerant, etc.

Each one of the plurality of the laminates 11 includes segments 301 of one or more of a plurality of primary heat transfer surfaces 30. Each one of the plurality of the laminates 11 further includes segments 401 of one or more of a plurality of secondary heat transfer surfaces 40. The primary heat transfer surfaces 30 are disposed to come into contact with both the first and the second fluids F1 and F2.

With the laminates 11 coupled together, the segments 301 and 401 of the respective pluralities of the primary heat transfer surfaces 30 and the secondary heat transfer surfaces 40 are configured to form respective pluralities of first flow pathways 50 and second flow pathways 60, which are oriented transversely with respect to one another. The first fluid F1 is directed to flow along the first flow pathways 50 and the second fluid F2 is directed to flow along the second flow pathways 60. In doing so, the first and second fluids F1 and F2 experience heat transfer directly across the plurality of the primary heat transfer surfaces 30 or indirectly across the plurality of the primary heat transfer surfaces 30 by way of the plurality of the secondary heat transfer surfaces 40

In order to increase the surface area of the plurality of the primary heat transfer surfaces 30 and to increase the turbulence of the flows of the first and second fluids F1 and F2 to thereby increase thermal performance of the heat exchanger 10, at least one of the plurality of the primary heat transfer surfaces 30 is corrugated. This corrugation may be defined along a length of at least one of the plurality of the first flow pathways 50 along the second dimension D2.

The segments 301 include end segments 3010, which bookend each laminate 11. These end segments 3010 are configured, such that when the laminates 11 are coupled together, the end segments 3010 cooperatively form a primary heat transfer surface 30 as well as a body 35, which may be employed to secure the heat exchanger 10 within a larger structure and/or which may define internal plenums in which the first or the second fluid F1 or F2 are provided or as a jig feature 351 to aid in the building of laminates 11 into a full heat exchanger 10.

In accordance with embodiments, each one of the laminates 11 may include each of the segments 301 of each one of the plurality of the primary heat transfer surfaces 30. Each segment 301 corresponds to each of the primary heat transfer surfaces 30 with all of the segments 301 arranged in a side-by-side array 31 that extends along the third dimension D3. For each laminate 11, spacers 32 may be provided in between adjacent ones of the segments 301 to define a height or thickness of the first flow pathways 50 in the third dimension D3. The spacers 32 are thinner than the segments 301 along the first dimension D1 such that entrances to the first flow pathways 50 between the spacers 32 are formed. Each one of the laminates 11 may further include the segments 401 of each one of the plurality of the secondary heat transfer surfaces 40. The segments 401 serve as fins extending transversely from corresponding segments 301 of the primary heat transfer surfaces 30.

The laminates 11 are coupled together by various processes, such as brazing, diffusion bonding and/or welding, along the first dimension D1. With the laminates 11 coupled together, the segments 301 of the plurality of primary heat transfer surfaces 30 and the segments 401 of the plurality of the secondary heat transfer surfaces 40 cooperatively form the first flow pathways 50 as having a similar width dimension and a longer length dimension (due to the corrugation) than the heat exchanger 10 as a whole. In addition, with the laminates 11 coupled together, the segments 301 of the plurality of primary heat transfer surfaces 30 and the segments 401 of the plurality of the secondary heat transfer surfaces 40 cooperatively form the second flow pathways 60 such that the second flow pathways 60 extend transversely or, in some cases, perpendicularly, to the first flow pathways 50.

Still referring to FIGS. 1-3 and with additional reference to FIG. 4, the corrugation of the at least one of the plurality of the primary heat transfer surfaces 30 is defined along the second dimension D2 and provides for an increase in surface area of the primary heat transfer surfaces 30 for a given overall heat exchanger 10 length. The corrugation may be repeated along the second dimension D2 as necessary for the desired thermal performance of the heat exchanger 10, and may be angular (see FIGS. 1-3), smooth, such as in sine wave corrugation (see FIG. 4) and/or provided in another configuration.

While the invention has been described in detail in connection with only a limited number of embodiments, it should be readily understood that the invention is not limited to such disclosed embodiments. Rather, the invention can be modified to incorporate any number of variations, alterations, substitutions or equivalent arrangements not heretofore described, but which are commensurate with the spirit and scope of the invention. Additionally, while various embodiments of the invention have been described, it is to be understood that aspects of the invention may include only some of the described embodiments. Accordingly, the invention is not to be seen as limited by the foregoing description, but is only limited by the scope of the appended claims. 

1. A heat exchanger through which first and second fluids flow in a heat transfer arrangement, the heat exchanger comprising a plurality of laminates coupled together, each laminate comprising: segments of a plurality of primary heat transfer surfaces disposed to contact the first and second fluids; and segments of a plurality of secondary heat transfer surfaces disposed to contact the first and/or second fluid, the segments of the respective pluralities of the primary and secondary heat transfer surfaces being configured to form respective pluralities of first and second flow pathways along which the first and second fluids flow, respectively, in the heat transfer arrangement, and at least one of the plurality of the primary heat transfer surfaces being corrugated along a length of at least one of the plurality of the first flow pathways.
 2. The heat exchanger according to claim 1, wherein the first and second fluids respectively comprise first and second flows.
 3. The heat exchanger according to claim 1, wherein the at least one of the plurality of the primary heat transfer surfaces is repeatedly corrugated.
 4. The heat exchanger according to claim 1, wherein the at least one of the plurality of the primary heat transfer surfaces is angularly corrugated.
 5. The heat exchanger according to claim 1, wherein the at least one of the plurality of the primary heat transfer surfaces is smoothly corrugated.
 6. The heat exchanger according to claim 1, wherein the segments of each one of the plurality of the primary heat transfer surfaces are arranged in a side-by-side array.
 7. The heat exchanger according to claim 1, wherein the first and second flow pathways are oriented transversely with respect to one another.
 8. The heat exchanger according to claim 1, wherein the first and second flow pathways are perpendicular to one another.
 9. A heat exchanger through which first and second fluids flow in a heat transfer arrangement, the heat exchanger comprising a plurality of laminates coupled together, each laminate comprising: segments of a plurality of primary heat transfer surfaces disposed to contact the first and second fluids; and segments of a plurality of secondary heat transfer surfaces disposed to contact the first and/or second fluid, the segments of the respective pluralities of the primary and secondary heat transfer surfaces being configured to form respective pluralities of first and second flow pathways along which the first and second fluids flow, respectively, in the heat transfer arrangement, and each of the plurality of the primary heat transfer surfaces being corrugated along respective lengths of each of the plurality of the first flow pathways.
 10. The heat exchanger according to claim 9, wherein the first and second fluids respectively comprise first and second flows.
 11. The heat exchanger according to claim 9, wherein each of the plurality of the primary heat transfer surfaces is repeatedly corrugated.
 12. The heat exchanger according to claim 9, wherein each of the plurality of the primary heat transfer surfaces is angularly corrugated.
 13. The heat exchanger according to claim 9, wherein each of the plurality of the primary heat transfer surfaces is smoothly corrugated.
 14. The heat exchanger according to claim 9, wherein the segments of each one of the plurality of the primary heat transfer surfaces are arranged in a side-by-side array.
 15. The heat exchanger according to claim 9, wherein the first and second flow pathways are oriented transversely with respect to one another.
 16. The heat exchanger according to claim 9, wherein the first and second flow pathways are perpendicular to one another.
 17. A heat exchanger, comprising: a plurality of laminates coupled together to form a heat exchanger body through which first and second fluids flow in transverse directions, each one of the plurality of the laminates comprising: segments of a plurality of primary heat transfer surfaces disposed to contact the first and second fluids; and segments of a plurality of secondary heat transfer surfaces disposed to contact the first and/or second fluid, the segments of the respective pluralities of the primary and secondary heat transfer surfaces being configured to form respective pluralities of first and second flow pathways along which the first and second fluids flow, respectively, in a heat transfer arrangement, and at least one of the plurality of the primary heat transfer surfaces being corrugated along a length of at least one of the plurality of the first flow pathways.
 18. The heat exchanger according to claim 19, wherein the first and second fluids respectively comprise first and second flows. 